Discipline: Engineering (Track & Civil) Category: Specification

Manufacture and testing of pre-

assembled glued insulated rail
joints
ETA-01-01

Applicability
ARTC Network Wide 9 CRIA (NSW CRN)

Primary Source
ARTC NSW Standard TPS 05 Version 1.2

Document Status
Version Date Reviewed Prepared by Reviewed by Endorsed Approved
1.2 8 March 2011 Standards Manager Exec Manager CEO
Standards SS&P 16/3/2011

Amendment Record
Version Date Reviewed Clause Description of Amendment
1.0 16 October 06 All Supersedes NSW Standard TPS 05 Version 1.2

1.1 21 November 06 3 Table showing live loadings expanded

1.2 8 March 2011 2 Table for 3.43 m GIJs removed

© Australian Rail Track Corporation Limited 2011

Disclaimer:
This document has been prepared by ARTC for internal use and may not be relied on by any other party without ARTC’s prior written consent. Use
of this document shall be subject to the terms of the relevant contract with ARTC.
ARTC and its employees shall have no liability to unauthorised users of the information for any loss, damage, cost or expense incurred or arising by
reason of an unauthorised user using or relying upon the information in this document, whether caused by error, negligence, omission or
misrepresentation in this document.
This document is uncontrolled when printed.
Authorised users of this document should visit ARTC’s intranet or extranet (www.artc.com.au) to access the latest version of this document.
Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Contents

Contents

1 Purpose .................................................................................................. 3

2 General description................................................................................. 3

3 Performance requirements ..................................................................... 4

4 Materials and components ...................................................................... 5

4.1 Materials.......................................................................................... 5
4.2 Rails ............................................................................................... 5
4.3 Fishplates ........................................................................................ 5
4.4 Insulating end post ........................................................................... 5
4.5 Bolts and nuts .................................................................................. 5
4.6 Swage fasteners ............................................................................... 5
4.7 Test certificates ................................................................................ 5
4.8 Identification of joints........................................................................ 5
4.9 Records ........................................................................................... 6

5 Manufacture ........................................................................................... 6
5.1 Cutting, bending and drilling............................................................... 6
5.2 Rail end hardening of 47kg rail............................................................ 6
5.3 Assembly, gluing and bolting .............................................................. 6

6 Production testing .................................................................................. 7

7 Delivery .................................................................................................. 7

8 Warranty ................................................................................................ 7

9 New product - prototype testing and approval ....................................... 8

9.1 General ........................................................................................... 8
9.2 Information to be provided ................................................................. 8

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Purpose

1 Purpose
This Technical Specification sets out ARTC’s requirements for the manufacture and testing of
pre-assembled, glued insulated rail joints to meet the requirements of the latest edition of AS
1085.12. In addition the requirements for production and prototype testing are specified.

2 General description
The insulated rail joint shall provide an electrical break in the rail for signalling purposes. It shall
consist of two lengths of rail rigidly joined by a pair of fishplates, insulating material, an
insulating end post separating the two rails, six high strength fasteners and other hardware,
such as washers, ferrules and bushes.
Overall length of the rail joint shall be specified on the Purchase Order. The minimum overall
length of joint should normally be 4.0 metres. Shorter joints may only be installed where track
conditions preclude longer lengths e.g. near turnouts. The tolerance on the length on
manufacture shall be +50/-0mm.
NSW standard curved 4.57m insulated rail joints are shown in Tables 1 below. If other length is
specified mid-ordinate details should be given on the purchase order.

Table 1 - 4.57 metre Long Glued Insulated Joint Curvature Tolerances

Nominal Radius Designated Mid Full Half Mid Ordinates

Ordinate Mid Ordinate
250m 10mm 8.5 to 11.5mm 1.5 to 3.5mm

500m 5mm 3.5 to 6.5mm 0.5 to 2.5mm

Straight 0 Clause 6 Clause 6

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Performance requirements

3 Performance requirements
The joints will be subjected to live loading as follows:

Rail Size 60kg/m 53kg/m 47/50kg/m

Nominal Axle Load/Speed combinations 30T @ 80 or 60km/h 25T @ 80km/h 25T @ 60km/h
(mostly at 60km/h)
25T @ 80km/h 23T @ 115km/h 23T @ 80km/h

23T @ 115km/h 21T @ 115km/h 21T @ 115km/h

Average Dynamic Wheel Load 370 kN 260 kN 260 kN

Estimated Number Of Load Cycles Per 2 Million 0.7 Million 0.7 Million
Annum

The joint will also be concurrently subjected to tensile or compressive forces up to 115 tonnes
caused by thermal rail expansion over the range of -10oC to +65oC.
The joint shall not bend or fail under vertical or lateral wheel loads and shall not deteriorate
during its service life in such a way that signal failure may occur as a result of electrical
conduction across the joint.
The joint shall also resist longitudinal slippage under thermal expansion and contraction effects
of the rail so that the insulated joint will not allow one rail to move relative to the other rail
within the joint in excess of that specified in clause 6.
The joints shall provide a minimum electrical resistance of 1 megohm rail to rail and rail to
fishplate.
Insulated rail joints shall be Grade A or Grade B in accordance with AS 1085.12. The grade
shall be specified by the Purchaser but would normally be Grade A for main lines and Grade B
for branch lines and sidings.

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Materials and components

4 Materials and components

4.1 Materials
All materials shall be free from defects and conform to the relevant Australian Standards.

4.2 Rails
Standard 50kg, 53kg and 60kg head hardened rail shall be in accordance with AS.1085.1 and
AS.1085.1 and shall be free from defects considered detrimental to service requirements.
Certificate of Conformance shall be provided upon request.
Head hardening of 50kg, 53kg and 60kg rails shall be in accordance with AS 1085.12.
Head hardened rail is not available for 47kg rail. 47kg/m insulated rail joints shall therefore be
manufactured from flame hardened standard carbon rail in accordance with clause 5.2.
Rails with a cross-section other than specified in AS 1085.1 shall be supplied only with the
written approval of ARTC.

4.3 Fishplates
Fishplates shall be of the six hole bar type and conform to the general requirements of
AS.1085.2. When fixed in position, fishplates shall be capable of supporting and transferring all
loadings between rails without relative movement between the rails and fishplates.
Adequate clearance shall be provided between the toe of the rail and the outer face of each
fishplate to allow electrical clearance between fishplates, bolts, nuts and fastenings.

4.4 Insulating end post

The profile of the end post shall be in accordance with AS 1085.12. The thickness shall be
6.0mm + 1mm-0.

4.5 Bolts and nuts

Bolts and nuts shall be minimum M24 steel bolts and nuts and washers of type equal to or
better than high strength bolts, nuts and washers described in AS/NZS.1252.

4.6 Swage fasteners

If swage fasteners are used, they shall be C50L type, M24mm high grade.

4.7 Test certificates

All material certificates and mechanical test certificates required by relevant Australian
Standards covering all components used in the joint shall be provided upon inspection.
If these certificates are not available, a letter of compliance to Australian Standards signed by
the Contractor will be acceptable.

4.8 Identification of joints

Each joint shall be marked with the information specified in AS.1085.12 such that it will remain
during the life of the joint.

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Manufacture

4.9 Records
A detailed record of all insulated joints produced by the Contractor shall be made available for
inspection at the Superintendent's request.

5 Manufacture

5.1 Cutting, bending and drilling

Cutting, bending and drilling shall be carried out in accordance with AS.1085.12.
Rail ends shall be angle cut with the rail ends at the insulating post cut at 15 degrees to the
right angle of the longitudinal axis (see Figure 1).

Figure 1 – Rail End angle

5.2 Rail end hardening of 47kg rail

The rail ends to be joined shall be flame hardened as specified in AS1085.12. Hardness testing
shall be in accordance with Appendix H of AS 1085.12
The Contractor shall document a quality plan or work procedure, and implement a flame
hardening process which ensures that the rail hardness is controlled.
Evidence that this requirement is being achieved shall be demonstrated upon request. A sample
for testing shall be supplied by the Contractor if requested.

5.3 Assembly, gluing and bolting

The insulated joint area of rail shall be prepared as specified by the adhesive manufacturer. The
joint shall be assembled in accordance to AS 1085.12.
The adhesive or gluing material shall be applied in accordance with the manufacturer's
instructions.
The bolts shall be installed so that alternate bolts face opposite directions and a washer shall be
placed under each nut.
The bolts shall be tensioned by turning the nuts in sequence 3 4 2 5 1 6 or 4 3 5 2 6 1.
The bolts shall be tensioned by a method approved by the Superintendent. The tension after the
adhesive has fully cured shall be at least 180 KN (800Nm). The manufacturer will be required to
demonstrate this tension during testing.
All bolts are to be readily removable to ensure adequate electrical clearances to the track
fastenings.
Where swage fasteners are used they shall be applied in accordance with the manufacturer’s
instructions and the requirements of AS 1085.12.

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
Production testing

6 Production testing
The complete joint shall have a smooth surface which shall not act as a trap for water, dust or
any element which may reduce its life.
The Superintendent shall have free access to the Contractor's works to ensure that all stages
and aspects of the joint manufacture are being carried out to the required standards.
Testing of the joints shall be carried out at the Contractor's works, at his expense, or at such
other location as may be agreed.
The Superintendent has the right to check any or all joints to ensure that they conform to the
requirements of this Specification.
All testing equipment shall be approved by the purchaser, tested in accordance with the
manufacturer’s instructions and certified for accuracy by an approved Testing Laboratory.
Production testing shall be undertaken in accordance with the table below.

Test Frequency Pass Criteria Description

Electrical Every joint Table 1 of 1085.12 Appendix C of AS 1085.12

Pull apart As specified in Table 1 of 1085.12 Appendix D of AS 1085.12

Appendix A of AS
1085.12

Alignment test Every joint Table 1 of 1085.12 Appendix G of AS 1085.12

Curve alignment Every curved joint As specified in clause Measurement of full mid-
where applicable 2 of this specification ordinate and half mid-ordinate

Hardness testing 1 in 10 joints As specified in clause Appendix H of AS 1085.12

of flame hardened 7.3.2 of 1085.12
rails

7 Delivery
After having been inspected and passed by the Inspector the insulated joints shall be delivered
to the destination specified on the Purchase Order.

8 Warranty
The Contractor shall be responsible for the total labour and material cost of in-track
replacement of any joint which fails due to faulty workmanship or material, except for rails,
within the first two (2) years of service life.

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Engineering (Track & Civil) Specification
ETA-01-01 Manufacture and testing of pre-assembled glued insulated rail joints
New product - prototype testing and approval

9 New product - prototype testing and approval

9.1 General
When submitting a prototype glued insulating rail joint for approval, it shall meet the
requirements of AS 1085.12 and this specification. The application shall be supported by the
results of the tests specified in Appendices C to H of AS 1085.12 which shall meet the pass
criteria specified in Table 1 of AS 1085.12.

9.2 Information to be provided

The following information and documentation shall be submitted by the Contractor and
approved by the Superintendent:-
1) Information as specified in Appendix B of AS 1085.12.
2) Material and Component Specifications. The use of materials to Foreign Standards may be
permitted provided that the Standards are not inferior to Australian Standards and will be
subject to the Superintendent's approval.
3) Certificate of testing carried out in accordance with the tests specified in Appendices C to H
of AS1085.12, verified by an independent testing organization such as a NATA accredited
laboratory.

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